Royal Enfield 2006 Thunderbird TwinSpark User manual

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FOREWORD
Congratulations on your choice of the Thunderbird TwinSpark. Your motorcycle represents a breakthrough in engineering
technology. It’s Unit Construction Engine delivers greater power and torque, while brand new ergonomics ensure
enhanced comfort and safety. Aesthetics have also been refined, resulting in a sleeker, more aerodynamic profile while
preserving the classic lines of the Thunderbird.
This manual is designed to give you complete control over your bike. It contains important information on efficient
operation and maintenance. We’ve also put in tips on riding safely, as well as some suggestions as to how you can
enhance your motorcycling experience.
Your safety is of prime concern to us and we urge you to be a responsible biker.Please make a careful selection of
riding gear in accordance with your application, style and weather conditionswhich will go a long way in providing you
with a feeling of confidence that goes on to enhance the riding and ownership pleasure that comes with this and every
other Royal Enfield machine.Also pleaseensure the same for your pillion rideras well. Respect the rules of the
Roadand ride safely.
Best of all, your Thunderbird TwinSpark automatically makes you a member of the legendary Royal Enfield community.
You can locate your nearest club or sign up for the next big ride at www.royalenfield.com
Enjoy the Trip!
We request you to carefully read the terms and conditions of warranty and other useful information given in this manual
before you begin to cruise on your Thunderbird TwinSpark.
SERVICE HEADQUARTERS
Royal Enfield, Tiruvottiyur High Road, Tiruvottiyur, Chennai-600019. Phone: [phone], Fax: [phone]
E-mail: [e-mail] Website: www.royalenfield.com

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All information in this manual is based on the latest product information available at the time of
publication. Due to continues improvements or other changes, there may be discrepancies
between information in this manual and your vehicle. Royal Enfield reserves the right to make
product changes at any time without prior notice and without incurring any obligation to
make same or similar changes to vehicles previously built or sold.
All images shown are for reference only and to explain. They need not to be exactly the same
on the model you own. Technical specifications are subject to change without prior notice.
“© Copyright 2006 Royal Enfield. All Rights Reserved. No part of this manual shall be copied,
distributed or otherwise dealt, without the express permission in writing of Royal Enfield.
NOTICE
Part No. 580589/b /Qty. 500/Oct. ‘10

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Personal and vehicle information..............4
Free service record..................................5
Specifications.......................................... 6
Safety Definitions.....................................9
Safe and happy riding...........................10
Vehicle identification numbers...............11
Location of key parts.............................12
Operation of controls............................16
Pre-Operational Checks........................22
Running in............................................ 23
Starting..................................................24
Gear Shifting, Riding & Stopping...........26
Parking..................................................27
Tools & First aid kit.................................28
Periodical maintenance chart...................29
Recommended lubricants......................31
Do it yourself.........................................32
Washing procedure...............................42
CONTENTS
Storage precautions................................43
Long trip precautions.............................. 45
Caring for Mileage................................46
Wiring diagram......................................48
Trouble shooting....................................49
Warranty terms and conditions.............56
Emission Warranty.................................58
All india Road Signs...............................63
Regional & Area Offices........................64
Log Book...............................................65
Free Service coupons.............................68
Paid Service/Maintenance Record......... 77
Notes.....................................................85
ANNEXURES
Vehicle Installation Form
Pre-Delivery Inspection Report
Bike Installation Confirmation By Cutomer
Form 22

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PERSONAL & VEHICLE INFORMATION
Name
Door No./Street
Locality
City State Pin
Contact Nos. Res: Off: Mobile : Email :
Engine No. Battery No.
Frame No. Battery make
Reg. No. Licence No.
Date of Sale Valid till dt.
Model Key No.:
Tyre make Colour
Sold by Dealer Code
Vehicle Installation Form (VIF) No.

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It is our endeavour to provide excellent service to your Thunderbird Twinspark at all times.
Towards this we provide four free services at specific Intervals.
Please avail these services at the specified time, in any of the Royal Enfield Dealerships /
Authorised service centres nearest to you and as a token of satisfactory services, kindly return
the free service coupon duly filled in and signed, to the service outlet.
Availing the free services in the specified time is a prerequisite to warranty consideration.
The cost of fuel, oil, grease etc. used for free service is chargeable to the customer.
FREE SERVICE RECORD
Note : Please ensure that the free service details are recorded in this sheet immediately after the
service is carried out.
Date of Service
Kms Covered
Servicing
Dealer’s Name
Address
1
ST
Service 4
th
Service2
nd
Service 3
rd
Service

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SPECIFICATIONS
Engine and Engine systems
Engine Type..................4 Stroke, air cooled,
...................................single cylinder
Bore............................70mm
Stroke..........................90mm
Swept volume...............346cc
Compression ratio........ 8.5:1
Max Torque @ rpm....... 28 Nm @4000 rpm
Idle rpm.......................1050±200 rpm
Starting........................E’Start
Air filter element...........Paper element
Carburettor..................Ucal - BS 29
Lubrication...................Wet Sump
...................................pressure lubrication
Engine oil capacity......... 2.75 lits
Engine oil grade...........Motul 3000 4T Plus
...................................15W 50 API SL Grade
Cooling.......................Natural air flow
Transmission
Clutch.........................Wet multiplate (6plates)
Primary drive................3/8” Duplex chain
...................................& sprocket
Primary ratio.................2.15 : 1
Gear box.....................Constant mesh 5 Speed
Gear ratio.................1
st
- 3.06 : 1
...............................2
nd
- 2.01 : 1
................................3
rd
- 1.52 : 1
................................4
th
- 1.21 : 1
................................5
th
- 1 : 1
Secondary drive...........5/8” Chain & Sprocket
Secondary ratio............2.53 : 1
Drive Chain links..........100 L
F.D. Sprocket................15 T

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SPECIFICATIONS
Chassis
Frame..........................Tubular
Suspension : Front...... Telescopic, hydraulic
...................................damping, Stroke 130 mm
Rear........ Swing arm with
...................................gas shock absorbers
Fr. Fork oil capacity..... 265 cc+ 2.5 cc per
...................................limb assy
Front fork oil make..... 1F Grade Gabr iel /
........................................Royal Enfield Fork Oil
Brakes : Front..... Hydraulic 280 mm
...................................ventilated disc
Rear....... Foot operated 153 mm
...................................single lead, internal
...................................expanding
Brake Oil Capacity..... 60ml
Brake Oil Grade......... DOT 3 or DOT 4
Tyre size : Front...... 3.25´´ ×19´´
...................................- 4PR/6PR
Rear....... 3.5´´ ×19´´
...................................- 4PR/6PR
Tyre pressure
Solo : Front..... 1.41 kg/cm
2
(20psi)
Rear....... 2.11kg/cm
2
(30psi)
With Pillion : Front..... 1.54 kg/cm
2
(22psi)
Rear....... 2.25 kg/cm
2
(32psi)
Steering lock................In built
Fuel tank capacity....... 13.5 litres (MIN)
Reserve.......................2 litres
Electricals
Generation................. Alternator AC-3
Phase
System.........................12V - DC
Ignition.......................Digital Dual spark
...................................Ignition TCI System
Battery..........................12V - 14AH
Spark plug...................Mico-WR5DC - 1 No.
...................................Bosch-UR5DC - 1 No.

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Spark plug gap........... 0.7 to 0.8 mm
Head lamp..................12V, 35 / 35W
Halogen bulb
Tail lamp.....................12V, 5W
Brake lamp..................12V, 21W
Speedometer lamp...... 12V, 3.4W - 1 No.
Hi beam indicator........ 12V, 1.7W
Neutral lamp Tell tale.. 12V, 1.7W - 1 No.
Turn Signal Tell Tale..... 12V, 1.7W - 2 Nos.
Turn signal..................12V, 10W - 2 Nos.
Horn...........................12V DC
Starter Motor..............0.7KW
Weights
Kerb weight.................182 Kgs.
Max. pay load.............168 Kgs.
Dimensions
Length.........................2120 mm
Width...........................780 mm
Height..........................1080 mm
Wheel base...................1370 mm
Ground clearance......... 135 mm
Saddle height...............750mm
Performance
Max. speed...................120 Km/hr
SPECIFICATIONS
 Values given above are for your guidance only.
 In view of continuous improvements being done on our products, the specifications are likely to
change without prior notice.

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The information given under the titles : Warning, Caution and Note are for your safety and for
the care and safety to your motorcycle and others. Please read these carefully and if disregarded
may result in injury to yourself or others and damages to the motorcycle.
Warning :
Indicates a potentially hazardous situation. Disregarding this message may result in injury to
rider or other persons.
C a u t i o n :
This message if disregarded may result in damage to the vehicle.
N o t e :
Indicates important and useful messages for clear understanding.
SAFETY DEFINITIONS

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SAFE AND HAPPY RIDING
Riding dress
 A proper riding apparel
N o t e :
 A light coloured shirt enables greater visibility
to other road users especially during nights.
C a u t i o n :
 Loose clothing may get caught on moving
parts of your motor-cycle.
 A pair of riding boots or shoes.
 Soft leather gloves.
 Goggles or spectacles to safe guard eyes.
 An ISI certified helmet. Affix light reflecting
strips of stickers at the front and rear.
Sitting posture
Correct sitting posture is a pre-requisite for stable
and safe riding :
 Sit Straight with your shoulders completely
relaxed.
 Keep your elbows close to your body.
 Keep your toes in straight ahead direction.
 Slightly press the petrol tank with the knees.
 Hold the handle grip close to its inner end.
 Look extensively, including rear view mirror,
without turning the head.
Braking
 Use both front and rear brakes together
for maximum braking efficiency.
Warning :
 Applying any one of the brakes suddenly may
cause the vehicle to skid.
 The hydraulic disc brake, fitted on your
Thunderbird Twinspark requires very less
effort an d high ef fort or sudden
application may lock the wheel. Please use
ut mos t caut ion w hil e appl ying the
hydraulic disc brake.
 Wh ile riding on wet or ba d road
conditions use brakes cautiously.

11
VEHICLE IDENTIFICATION NUMBERS
Frame Number
Punched on steering head tube RH side.
Engine Number
Punched on top of the engine LH side.

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LOCATION OF KEY PARTS
1. Trip meter knob
2. Speedometer
3. High beam indicator
4. Neutral indicator
5. RPM meter
6. Fuel Gauge
7. Turn signal indicator RH
8. Turn signal indicator LH
N
1 2 3 4 5 6
7
8

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LOCATION OF KEY PARTS
1. Clutch lever
2. Head lamp dimmer switch
3. Turn signal switch
4. Handle bar
5. Head light switch
6. Ignition Kill switch
7. Front brake lever
8. Throttle control
9. E-Start Button
10. Horn button
1
234 5
6
7
8
9
10

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LOCATION OF KEY PARTS
11. Horn
12. Rear brake pedal
13. Kick Starter lever
14. Silencer
15. Rear number plate
1. Rear Trafficator
2. Side panel RH
3. Side panel lock
4. Carburetor
5. Fuel tank
6. Fuel tank cap
7. Front Trafficator
8. Head light
9. Front number plate
10. Steering lock
12 3 4
5
67
8
9
10
11
1213
14
15

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LOCATION OF KEY PARTS
1 2 3 4 5 6
8
9
10
11
12
11. Rider foldable foot rest
12. Gear shift lever
6. Pillion back rest
7. Tail lamp
8. Pillion foot rest
9. Side Stand
10. Center Stand
1. Fuel tap
2. Side panel LH
3. Side panel lock
4. Seat
5. Side handle
7

16
Electric Start Switch
Depress gently to start Engine
OPERATION OF CONTROLS
Ignition switch
OFF
ON

17
OPERATION OF CONTROLS
Ignition Stop switch
OFF
ON
Head light switch
OFF
Pilot ON
Head lamp ON

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OPERATION OF CONTROLS
Dimmer switch
High beam
Low beam
Day Flash
Turn signal switch
Left turn signal ON
OFF (Push to Cancel)
Right turn signal ON